Detroit Diesel 60 User manual

DDC-SVC-MAN-0039

Specifications are subject to change without notice. Detroit Diesel Corporation

Printed in U.S.A.

13400 Outer Drive, West, Detroit, Michigan 48239-4001

Telephone: 313-592-5000

www.detroitdiesel.com

EPA04 Series 60

®

Operator’s Manual

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

To the Operator

This guide contains instructions on

the s afe operation and preventive

maintenan c e of your Detroit Diesel

Series 60® engine used in vehicle or

ﬁre ﬁghting apparatus applications.

Maintenance i nstructions cover

routine engine services such as lube

oil and ﬁlter changes in enough detail

to permit self-servicing, if desired.

The operator should become fam ili ar

with the contents o f this guide before

operating the engine or carrying out

maintenance procedures.

Power-driven equipment is only

as safe as the person operating the

controls. You are urged, as the

operator of this diesel engine, to keep

ﬁngers and clothing away from the

revolving belts, drive shafts, pulleys,

etc. on the engine installatio n.

Throughout this guide CAU TION S

regarding personal safety and

NOTICES regarding engine

performance or service life will

appear. To avoid personal injury and

ensure long engine service life, always

heed these instructions.

Whenever possible, it will beneﬁ t

youtorelyonanauthorized Detroit

Diesel service outlet for all your

service needs from maintenance to

major parts replacem ent. Authorized

service outl e ts worldwid e s tock

factory-original parts and hav e

the specialized equipment and

experienced, trained personnel

to provide prompt preventive

maintenance and skilled engine

repairs.

The information and speciﬁcations

in this publication are based on the

inform ation in effect at the time of

approval for printing. Contact an

authorized Detroit Diesel service

outlet for inf ormation on the latest

revision. The right is reserved to

make chan ges at any time withou t

obligatio n.

All inform ation subject to change without notice. i

NOTICE:

Coolant m ust be inhibited w ith the

recommended SCAs (supplemental

coolant additives) listed in the

How To section of this engine

operator's guide. In addition, the

engine can be eq uipped with a

coolant ﬁlter/inhibitor system as an

installed option or as an after-sale

item. Failure to check and

maintain SCA levels at required

concentrations will result in

severe damage ( corrosion) to

the engine cooling system and

related components.

WARRANTY

The ap plicable eng ine warranty is

contained in the booklet “Warranty

Information f or Series 60 Engines,”

available from auth orized Detroit

Diesel service outlets.

Keep this Operator's Guide

with the engine installation at

all times. It contain s important

operating, mainten ance, and safety

instructions.

Trademark Information

DDC®, Detroit Diesel®, DDEC®,

Series 60®, Optimized Idle®,

Diagnostic L ink ®, reliabilt®,

POWER Trac®, POWER COOL®,

and POWER GUAR D® are registered

trademarks of Detroit Diesel

Corporation. Delco Rem y® is a

registered trademark of Delco Remy

America, Inc. Bosch® is a registered

trademark of Robert Bosch Company

N.A. Fuel Pro®, and Mega Filter®

are registered trademarks of Davco

Manufacturing, L.L.C. PowerBand®

is a registered tradem ark of Gates

Rubber Company. Tectyl® is a

registered trademark of Daubert

Chemical Company, Inc. Biobor® is a

registered tradem ark of United States

Borax and Chemical Corporation.

DuPont® is a registered tradem ark

of E.I. DuPont de Nemours and

Company, Inc. All other trademarks

used are the property of their

respective owners.

ii All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

TABLE OF CONTENTS

INTRODUCTION ............................................... ........................ ........... 1

NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1

CAUTION SUMMARY ....................................... ........................ ........... 3

ENGINE OPERATION ..................................................................... 3

PREVENTIVE MAINTEN ANCE ....................................................... 4

ELECTRICAL SYSTEM ................................................................... 7

COO LING SYSTEM ......................................................................... 8

AIR INTAKE SYSTEM ............................................ ............... ........... 8

FUEL SYSTEM .......................................... ............... ....................... 9

STARTING AIDS .............................................................................. 9

COMPRESSED AIR ......................................... ............ ............ ........ 11

LUB RICATING OIL AND FILTERS ........................ .......................... 11

ENGINE MODEL AND SERIAL NUMBER DESIGNATION .............. .. 12

CERTIFICATION L ABELS .................................. ............................. 13

OPERATING INSTRUCTIONS F OR A FIRST TIME START .............. 14

SYSTEM CHECKS ...... ........................... ....................................... .. 14

COO LING S YSTEM CH ECKS ........ ............... ............... .............. 14

LUB R ICATION SYSTEM CHECKS ....... ............... ....................... 15

EXT ENDED S TORAGE ................................ .......................... 15

FUEL SYSTEM CHECKS ............................................................ 16

OTHER CH ECKS ....................................................... ................. 17

STARTING THE ENGINE ................................................................ 17

INITIAL ENGINE START .................................................. ........... 18

ELEC TRIC STARTER ............................................................. 18

AIR STARTER ............................................ ........................ ..... 19

RUNNING THE ENGINE ............ ........................... .......................... 19

OIL PRESSU RE ................................................ ............... ........... 19

WARM- UP ........................ ........................ ................................... 19

INSPE CTION ........ ....................................................................... 19

TRANSMISSIO N ........................................ ............................. 19

FLUID LEAKS ......................................... ............ ............ ........ 19

CRANKCASE .......................................................................... 20

All inform ation subject to change without notice. iii

TABLEOFCONTENTS

TURBOCHARG ER ................ .................................................. 20

AVOID UNNEC ESSARY IDLING ................................................. 20

STOPPING THE ENGINE ................................................................ 2 0

EME RGENCY JUMP STARTING ..... ............... ........................... ..... 21

DDEC V S YSTEM .................................... ............ ........................ ........ 22

DDEC FEATURES ............. .............................................................. 22

ENGINE PROTECTION ..................... ......................................... 23

IDLE SHUTDOWN TIMER ........ .................................................. 23

CRUISE CONTROL . .................................................................... 2 3

ENGINE BRAKES ... ........................... ......................................... 25

DATA REC O RDING CAPABILITY ............................................... 26

DDEC V O PERATION ...................................................................... 26

STOP ENGINE OVERRIDE SWITCH .............................. ........... 27

IMMEDIATE SPEED REDUCTION ............................................. 27

RED STOP LAMP ........................................... ........................ ..... 27

DIAGNOSTIC DATA READER ............................. ....................... 28

DDEC V ENGINE DRIVIN G TIPS ....................................... ............ ..... 35

ACCELE RATING THE VEHICLE ............ ........................... .............. 35

CRUISE CONTROL .............. ........................................................... 35

ENGINE BRAKES AND CRUISE C O NTROL ................. ... ... ........... 37

SHIF TING ........ ........................ ............ ........................ ............ ........ 37

IDLING .................................. ........................ ................................... 39

WINTER FR ONTS ... ................................................ .................... 39

ENGINE BRA KE SYSTEM ............. ........................ ............ ................. 40

DRIVER CO NTRO L SWIT CHES ..................................................... 40

LOW/HIGH SW ITCH .................................................. ................. 40

LOW /MED/HI GH SWITCH .......................................................... 4 0

CLUT CH PEDAL AND TH R OTTLE POSITION CONTROLS .......... 40

ENG INE BRAK E OPERATION ... ....................................... .............. 40

ANTI-LOCK BRAKING SYST EMS ............. ............... ............... ........ 4 2

DRIVING O N FLAT, DRY PAVEMENT ................ ........................... .. 42

DESCENDING A LONG, STE EP GRADE ................... ............... ..... 42

DRIVING ON WET OR SLIPPERY PAVEME NT .............................. 44

ENGINE SYSTEMS ......... ............ ........................ ............ .................... 45

FUEL SYSTEM .......................................... ............... ....................... 45

LUB RICATION SYSTEM ....................................... .......................... 45

iv All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

AIR SYSTEM ........................................................................... ........ 45

COO LING SYSTEM ......................................................................... 4 5

ELECTRICAL SYSTEM ................................................................... 45

EXHAUST SYSTEM ........................................................................ 45

EXHAUST G AS R ECIR CULATION SYSTEM .................................. 45

MAINTENANCE .................................... ........................ ............ ........... 46

MAIN TENANCE INTERVALS .................................................. ........ 46

PREVENTIVE MAINTENANCE INTE RVALS .......................... ........ 56

ITEM 1 – LUBRICATING OIL .............................................. ........ 5 6

ITEM 2 – FUEL AND FUEL TANK ............ ........................... ........ 5 7

ITEM 3 – F UEL LINES, FLEXIBLE HOSES ... ............................. 59

LEAKS ............................................................................. ........ 59

HOSES AND F ITTINGS ............................................ ............ .. 59

HOSE SERVICE LIFE ................................... .......................... 59

ITEM 4 – COOLING SYSTEM ............................................. ........ 60

COO LANT LEVEL ................................................................... 60

COO LANT INHI BITORS ........................................................ .. 60

COO LANT D RAIN INTERVAL ..... ............................................ 60

ITEM 5 – TURB OC HARGER , AIR-TO-AIR CHARGE COOLER . 62

WASTEGATED T URBOCHA RGERS ...... ... ............... ... ... ........ 6 2

ITEM 6 – BATTERY ........................................ ............................. 63

ITEM 7 – TACHOMETER DRIVE ................ ............... ................. 64

ITEM 8 – DRIVE BELTS .............................................................. 64

V-BELTS ................................................................. ................. 64

2-GR OOVE POWERBA N D ........................... .......................... 65

12–RIB POLY-V BELT ..... ........................................................ 65

BELT R EPLACEMENT . ........................... ................................ 6 6

ITEM 9 – A IR COMPRESSOR ....................... ........................... .. 66

ITEM 10 – AIR CLEANER ... ............... ......................................... 66

AIR CLEANER REPLAC EMENT ................ ............... ... ........... 67

ITEM 11 – LUBRICATING OIL FILTERS ....................... .............. 67

ITEM 12 – FUEL FILTERS .. ........................................................ 68

FUEL PRO® 382 F ILTERS ..................................................... 68

SPIN- ON FILTERS ................................................. ................. 68

ITEM 13 – WATER PUMP AN D COOLANT INHIBITOR

ELEMENT .................................................................................. .. 68

WATER P UMP D RAIN HOLE ................................................. 6 8

COO LANT INHI BITOR ELEMENT ......................... ................. 69

All inform ation subject to change without notice. v

TABLEOFCONTENTS

ITEM 14 – CRANKING MOTOR .................................................. 69

ITEM 15 – AIR SYSTEM ............................................................. 69

ITEM 16 – EXHAUST SYSTEM ............ ... ............... ............... ..... 70

ITEM 17 – ENGINE (STEAM C LEAN) ... ............... ....................... 70

ITEM 18 – RADIATOR ...... ........................................................... 70

ITEM 19 – OIL PRESSURE .... ........................... ............... ........... 71

ITEM 20 – BATTERY-CHARGING ALTERNATOR ................. ... .. 71

BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ..... 72

GENERAL SERVICE REQUIREMENTS – BOSCH® AND

DEL C O REMY® ALTER N ATORS .......................... ................. 72

ITEM 2 1 – ENGINE AND TRANSM ISSI ON MOUNT S ................ 72

ITEM 22 – CRANKCASE PR ESSUR E ..... ........................... ........ 72

ITEM 23 – FAN HU B ......................................................... ........... 72

ITEM 24 – THERM OSTATS AND SEALS ......... ............... ........... 72

ITEM 25 – CRANKCAS E BREATHER .. ... ............... ... ............... .. 73

ITEM 26 – ENGINE TUNE-UP ................................ .................... 7 3

ITEM 27 – VIBRATION DAMPER ..................................... ........... 74

HOW-TO SECTION .................................. ............ ........................ ........ 75

HOW TO SELECT LUBRI CATING OIL ...... ............... ............... ........ 7 5

LUB R ICANT REQUIRE MENTS ....................................... ........... 75

EGR-EQUIPPED ENGINES .................................................... 75

NON-EGR ENGIN ES .............................................................. 75

ENGINES BUILT PRIOR TO 1998 .......................................... 75

COLD WE ATHER STARTING ................................................ ..... 76

SYNT HETIC OILS ...... ................................................ ................. 76

THE USE OF SUP P LEMENTAL ADDITIVES .............................. 77

WHEN TO CHANGE OIL ................................................... .............. 77

DISPOSING O F WASTE O IL ............................ .......................... 78

HOW TO REP LACE THE LUBE OIL FILTERS ...... ............... ........... 78

REPLACE SPIN-ON TYPE OIL FILTER .................. ............... ..... 78

HOW TO SELEC T FUEL OIL .............. ............................................ 8 0

QUALITY .......................... ........................ ............ ....................... 80

FUEL CONTAMINATION ....................... ........................... ........... 80

PRO HIBITED ADDITIVES ............... ........................... ................. 81

USED LUBRIC ATING OIL .................................................. ..... 81

GASOLINE ............................................................................. 81

HOW TO REPLACE THE FUEL FI LTERS ............................ ........... 81

REPLACE SPIN-ON PRIMARY OR SECONDARY ELEMENTS 82

vi All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

REPLACE FUEL/WATER SEPARATOR ELEMENT .................. .. 84

REPLACE FUEL PRO ELEMENT ...... ............... ............... ........... 85

ENG INE OUT OF F UEL — HOW TO RESTART ............... ... ... ........ 8 7

ENG INES WI TH SPIN-ON FILTER S ..... ........................... ........... 87

ENG INES WI TH FUEL PRO FILTERS ................................ ........ 88

HOW TO SELEC T COO LANT .... ..................................................... 89

DEF INITION S .............................................. ........................ ........ 89

APPROVED COOLANTS . ........................... ................................ 9 0

EG & WATER OR P G & WATER PLUS SCA INHIBI TOR ....... 91

MIXING EG OR PG ANTIFREEZ E AND WATE R ........... ... ... .. 91

RECYCLED ANTIFREEZE ........... ........................... .............. 94

EG/WATER+OATINHIBITORORPG/WATER+OAT

INHIBITOR ....... ............ ................................................ ........... 94

WATER ONLY + SCA O R WATER ON LY + OAT INHIBITOR 95

WATER R EQUIREMENTS .................................... ................. 96

COOLANTS NOT RECOMM E NDED ................ ............... ........... 96

ALL ANTIFREEZES AND COOLANTS CONTAINING

PHOSPHATE ................ .................................... ....................... 96

AUTOMOT IVE TYPE COOLANTS ............................ ... ........... 96

METHYL ALCOHOL-BASED AN TIFREEZE . ............... ........... 96

GLYCOL-BASE D COOLANTS FORMULATED FOR HVAC ... 97

ADDITIVES NOT RECOMMEND ED ....................... ............... ... .. 97

SOLU BLE OIL ADDIT IVES .................. ........................... ........ 9 7

CHROMATE ADDITIVES ............... ........................... .............. 97

COO LANT INHI BITOR TEST INTERVALS ......................... ........ 97

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

FORM ULATED COOLANT ............ ............... ............... ........... 98

MAIN TENANCE INTERVALS ... ....................................... ........ 98

SCA TEST PROCEDURES ....... ....................................... ........... 100

NEED RELEASE COOLANT FILTERS (NON-OAT SYSTEMS) . 101

DROPOUT ... ............ ........................ ............ ........................ ........ 102

EXTENDER INHIBITOR ADDITIVE FOR “OAT” COOLANT ....... 102

OAT COOLANT DRAIN INT ERVAL ........ ............... ................. 103

CHRONI C COOL A NT SYSTEM PROBLE MS ......... ... ... ... ........... 103

COOL ING SYST EM MAINTENANC E PRO DUCTS ... ... ... ........... 103

POWER COOL SC AS ............................................................. 103

POWER COOL CO OLANT FILTER ELEME NTS .................... 103

POWER COOL CLEANERS ................ ................................... 103

All inform ation subject to change without notice. vii

TABLEOFCONTENTS

SUMMARY OF COOLANT RECOMMENDATIONS .................... 104

COO LANT LIF E OF GLYCOL COO LANT ........ ....................... 105

COO LANT LIFE OF OAT COOLANT .............................. ........ 105

COO LANT LIFE OF OTH ER COOLANTS .............................. 105

HOW TO DRAIN AND FL U SH THE COOLING SYSTEM . ... ... ... ... .. 106

HOSES .................... ........................ ............ ........................ ........ 107

WHEN TO SERVICE THE DRY TYPE AIR CLEANER ..... ... ... ... ... .. 107

BASIC TROUBLESHOOTING ............................. ........................ ........ 108

ENGINE STORAGE ........................ ........................ ............ ................. 113

PREPARING ENGINE FOR STORAGE ................ ............... ........... 113

TEMP ORARY S TORAGE ( 30 DAYS OR LESS) ....................... .. 113

EXTE NDED STORA GE (MO R E THA N 30 DAYS) ........... ... ........ 114

RESTORING AN ENG INE AFTER EXTENDE D STORAGE ....... 117

SERIES 60 SERVICE PUBLICATIONS .................. ............ ................. 119

CUSTOMER ASSISTANCE ..................... ............ ........................ ........ 120

ROA D SERVICE I N THE U.S. OR CANADA ... ... ............... .............. 123

WORKING WITH DDC SERVICE OUTLETS ........ ............... ........... 123

LIMITED WARR ANTY ON HIGHWAY VEHICLE ENGINES .......... ..... 126

TER MS O F COVERAGE ................................................................. 126

USES ................. ............................................................ .............. 126

DEF ECTS .................................................... ........................ ........ 126

REPAIRS .............. ........................ ........................ ............ ........... 126

WARRANT Y PE RIOD .................................................................. 1 26

LIKE REPLA C EMENT ENGINE ... ............... ............... ................. 126

SERVICE SUPPLIES .......... ........................................................ 127

ENG INE REMO VAL AND REINSTALLATION ......... .................... 127

THIS WARRANT Y DOES NOT COVER: ........................... .............. 127

REPAIRS D UE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEG LI G ENCE OR CERTAIN MODIFICATIONS ................. ... ..... 127

BRAKING DEVICES ................................................... ................. 1 28

FUEL INJECTORS AFTER 200,000 MILES/320,000

KILO METE RS ........................................ ............ ........................ .. 128

MAINTENA NCE .......... ................................................................. 1 28

INCIDENTAL OR CONSEQUENTIAL DAMAGE ........... ... ... ... ... .. 128

OTHER LIM ITATIONS ................................. ................................ 128

viii All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

LIMITED WARRANTY ON URBAN BUS, MOTOR COACH OR

MOTOR HOME ENGINES ......................................... ............ .............. 130

TER MS O F COVERAGE ................................................................. 130

USES ................. ............................................................ .............. 130

DEF ECTS .................................................... ........................ ........ 130

REPAIRS .............. ........................ ........................ ............ ........... 130

WARRANT Y PE RIOD .................................................................. 1 30

SERVICE SUPPLIES .......... ........................................................ 130

LIKE REPLA C EMENT ENGINE ... ............... ............... ................. 131

ENG INE REMO VAL AND REINSTALLATION ......... ... ............... .. 131

THIS WARRANT Y DOES NOT COVER: ........................... .............. 131

REPAIRS DUE TO ACCIDENTS, MISUS E , ALTERATION,

STORAGE DAMAGE, NEGLIGENC E OR C ERTAIN

MODIFICATIONS . ............ ........................................................... 131

BRAKING DEVICES ................................................... ................. 1 32

FUEL INJECTORS AFTER 200,000 MILES/320,000

KILO METE RS ........................................ ............ ........................ .. 132

MAINTENA NCE .......... ................................................................. 1 32

INCIDENTAL OR CONSEQUENTIAL DAMAGE ........... ... ... ... ... .. 132

OTHER LIM ITATIONS ................................. ................................ 132

LIMITED WARRANTY ON FIRE TRUCK OR CRASH RESC UE

VEHICLE ENGINES ........................ ........................ ............ ................. 134

TER MS O F COVERAGE ................................................................. 134

USES ................. ............................................................ .............. 134

DEF ECTS .................................................... ........................ ........ 134

REPAIRS .............. ........................ ........................ ............ ........... 134

WARRANT Y PE RIOD .................................................................. 1 34

LIKE REPLA C EMENT ENGINE ... ............... ............... ................. 134

SERVICE SUPPLIES .......... ........................................................ 134

ENG INE REMO VAL AND REINSTALLATION ......... ... ............... .. 135

THIS WARRANT Y DOES NOT COVER: ........................... .............. 135

REPAIRS DUE TO ACCIDENTS, MISUS E , ALTERATION,

STORAGE DAMAGE, NEGLIGENC E OR C ERTAIN

MODIFICATIONS . ............ ........................................................... 135

MAINTENA NCE .......... ................................................................. 1 35

INCIDENTAL OR CONSEQUENTIAL DAMAGE ........... ... ... ... ... .. 136

OTHER LIM ITATIONS ................................. ................................ 136

All inform ation subject to change without notice. ix

TABLEOFCONTENTS

SPECIFICATIONS ................................................... ........................ ..... 1 37

FUEL AND LUBRI CATING OIL REQUIRE MENTS ... .................. ..... 13 7

OIL PA N CAPACITY ...... .................................... ........................ .. 137

OIL PA N CAPACITY ............................................ .................... 137

TOTAL OIL CAPACITY OF THE EN G INE ..... .......................... 137

POWER COOL ENGIN E PRODUCTS .............................. .............. 138

FULLY FORM ULATED IEG CO OLANT ....................................... 138

LATIN A MERICAN COOLANT ..... ............................................... 138

2000 SUPPLEMENTAL COOLANT ADDITI VE ................ ... ... ... .. 139

3000 SUPPLEMENTAL ADDITIVE F ILTE RS .......... ... ............... .. 139

NEED RELEASE COOLANT F ILTERS ....................................... 140

PLUS EXTENDED LIF E OAT CO OLANT . ... ........................... ..... 140

PLUS EXTENDER F OR POW ER COOL PLUS OAT COOLANT 140

PLUS 6000 OAT INHIBITOR FOR WATER-ONLY S YSTEMS .... 141

COOLING SYSTEM CL EANERS ................... ............... ... ........... 141

COOL ANT TESTI NG AND ANALYSIS PRODUCT S .............. ..... 14 2

x All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

INTRODUCTION

This guide is intended for use by the

operator of a Detroit Diesel Series

60® engine used in the following

applications:

□ On-Highway Vehicles

□ Fire Truck or Crash/Rescue

Vehicles

Non-Genuine and Rebu ilt

Component Quality Alert

In recent years, electronic engine

controls have been instrumental

in aiding engine manufacturers in

meeting the stringent emission

requirements of the U.S.

Environmental Protection Agency

(U.S. EPA) and the California Air

Resources Board (CARB) and

also in meeting the ever-increasing

performance demands of the customer.

Maintenance procedures are t o

be followed in order to continue

satisfactory performance and

durability and to ensure coverage of

the engine under the manufacturer's

warranty. Many of these maintenance

procedures also ensure that the engine

continues to c om ply with applicable

emissions standards. The U .S.

EPA speciﬁcally d e ﬁnes an engine's

“useful emission life” — currently

established as 43 5,000 miles (700,0 00

kilometers) for on-highway engines.

Proper maintenance procedures, using

speciﬁc components engineered to

comply with emissions regulations,

may be performed by an authorized

Detroit D iesel distributor or d ealer,

an independent outlet or the op erator

or ow ner. The owner is responsible

for determining the suitability of

components to maintain emissions

compliance d uring the engine's useful

emission life.

Electronic contro ls and components

have signi ﬁcantly increased in

sophistication, b ut the fundamental

objective remains the same — precise

timing and delivery o f fuel. The v ery

heart of the Detroit Diesel Electronic

Controls (DDEC®) is the electronic

unit injector (EUI ). The p roper

functioning of the EUI is a bsolu tely

paramount if the beneﬁts of electronic

controls are to be realized. Detroit

Diesel Corporation has bui lt over

650,000 engines with electronic unit

injectors — more than anyone else in

the business.

Detroit Diesel cautions that the

indiscriminate rebuilding of precision

components, withou t the beneﬁtof

speciﬁcations, specialized equipm ent,

and knowledge of the electronic

operating system, will jeopardize

performance or lead to more serious

problems, and can take the engine

outside of compliance with U.S. EPA

or CA RB emissions standards.

All inform ation subject to change without notice. 1

INTRODUCTION

There a re other co mp onen ts in

an engine, such as turbocharger,

camshaft, piston, etc., which

are speciﬁcally designed and

manufactured to exacting standards

for emissions compliance. It is

important that these components, if

replaced, modiﬁed or substituted, can

be veriﬁed to ensure that the engine

remains in compliance with emissions

standards. The use of inadequately

engineered, manufactured or tested

components in repair or rebuild of

the engine may b e in violation of the

federal Clean Air A ct and applicable

U.S. EPA or CARB regulations.

Furthermore, modern engines exh ibit

operating parameters which require

the use of proper ﬂuids, such as

fuel, coolant and lubricating oil, to

maintain lon g engine life. Th e use of

ﬂuids that do not meet Detroit Diesel

Corporation speciﬁcations may result

in early wear out or engine failure.

2 All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

CAUTION SUMMARY

The following cautions must be

observed by the operator of the

vehicle o r e quipment in which this

engine is installed and/or by those

performing basic engine preventive

maintenance. Failure to read and

heed these cautions and exercise

reasonable care for personal safety

and the safety of others when

operating the vehicle/e qu ipment

or performing basic engine

preventive maintenance may result

in personal injury and engine

and/or vehicle/equipment damage.

Engine Operation

Observe the followin g cautions when

operating the engine.

PERSONAL INJURY

To avoid injury from loss of

vehicle/vessel control, the

operator of a DDEC equipped

engine must not use or read

any diagnostic tool while the

vehicle/vessel is moving.

PERSONAL INJURY

Diesel engine exhaust and some

of its constituents are known to

the State of California to cause

cancer, birth defects, and other

reproductive harm.

□ Always start and operate an

engine in a well ventilated

area.

□ If operating an engine in

an enclosed area, vent the

exhaust to the outside.

□ Do not modify or tamper

with the exhau st system or

emission control system.

PERSONAL INJURY

To avoid injur y from engine

shutdown in an unsafe situation,

ensure the operator know s how

to override the stop engine

condition on a DDEC-equipped

unit.

All inform ation subject to change without notice. 3

CAUTION SUMMARY

LOSS OF VEHICLE CONTROL

To avoid injury from loss of

vehicle control, d o not activate

the Engin e Brake system u nder

the following conditions:

□ On wet or slippery pavemen t,

unless the vehicle is equipped

with ABS (anti-lock braking

system) and you have had

prior experience driving

under these conditions .

□ When driving without a trailer

(bobtailing) or pulling an

empty trailer.

□ Ifthetractordrivewheels

begin to lock or there is

ﬁshtail motion after the

EngineBrakeisactivated,

deactivate the brake system

immediately if this occurs.

LOSS OF VEHICLE CONTROL

To avoid injury from the loss of

vehicle control, do not use cruise

control under these conditions:

□ When it is not possible to

keep the vehicle at a constant

speed (on winding roads, in

heavy trafﬁc, in trafﬁcthat

varies in speed, etc.).

□ On slippery roads

(wet pavement, ice-or

snow-covered roads, loose

gravel, etc.).

Preventive Maintenance

Observe the following cau tions when

performing preventative maintenance.

PERSONAL INJURY

To avoid injury when working

near or on an operating engine,

remove loose items of clothi ng

and jewelry. Tie back or contain

long hair that could be caught in

any m oving part causing injury.

4 All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

PERSONAL INJURY

To avoid injury when working

on or near an operating engine,

wear protective clothing,

eye protection, and hearing

protection.

HOT OIL

To avoid injury from hot oil, do

not o perate the engine with the

rocker cover(s) removed.

FIRE

To avoid inj ury from ﬁre, contain

and eliminate leaks of ﬂammable

ﬂuids as they occur. Failure to

eliminate leaks could result in

ﬁre.

USED ENGINE OIL

To avoid injury to skin from

contact with the contaminants in

used engine oil, wear protective

gloves and apron.

PERSONAL INJURY

To avoid injury when using

caustic cleaning agents, follow

the chemical manufactur ers

usage, disp osal, and safety

instructions.

PERSONAL INJURY

To avoid injury from hot surfac es,

wear protective gloves, or allow

engine to cool before removing

any component.

PERSONAL INJURY

To avoid injury, use care when

working around moving belts and

rotating parts on the engine.

All inform ation subject to change without notice. 5

CAUTION SUMMARY

FIRE

To avoid injury from combustion

of heated lubricating-oil vapors,

stop the engine immediately if an

oil leak is detected.

PERSONAL INJURY

To avoid injury from contact

with rotating parts when an

engine is operating with the air

inlet piping removed, install an

air inlet screen shield over the

turbocharger air inlet. The shield

prevents contact with rota t ing

parts.

HOT COOLANT

To avoid scalding from the

expulsion of hot coolant, never

remove the cooling syste m

pressure cap wh ile the en gine is

at oper ating temperature. Wear

adequate protective clothing

(face sh ield, rubber gloves,

apron, and boots). Remove the

cap slowly to relieve pressure.

FIRE

To avoid injury from ﬁre, do not

smoke or allow open ﬂames when

workingonanoperatingengine.

FIRE

To avoid injury from ﬁre from a

buildup of volatile vapors, keep

the engine area well ventilated

during operation.

PERSONAL INJURY

To avoid injury from rotating belts

and fans, do not remove and

discard safety guards.

6 All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

PERSONAL INJURY

To avoid injury from slipping and

falling, immediately clean up any

spilled liquids.

Electrical System

Observe the followin g cautions when

jump starting an engine, charging

a battery, or workin g with the

vehicle/application electrical system .

ELECTRICAL SHOCK

To avoid injury from electrical

shock, do not touch battery

terminals, alternator terminals, or

wiring cables while the engine is

operating.

Battery Explosion and Acid Burn

To avoid injury from battery

explosion or contact with battery

acid, work in a well ventilated

area, wear protective clothing,

and avoid sparks or ﬂames near

the battery. If you come in cont act

with battery acid:

□ Flush your skin with wa ter.

□ Applybakingsodaorlimeto

help neutralize the acid.

□ Flush your eyes w ith water.

□ Get medical a ttention

immediately.

PERSONAL INJURY

To avoid injury from accidental

engine startup while servicing

the engine, disconnect/disable

the starting system.

All inform ation subject to change without notice. 7

CAUTION SUMMARY

Cooling System

Observe the followin g cautions when

servicing the cooling system.

HOT COOLANT

To avoid scalding from the

expulsion of hot coolant, never

remove the cooling syste m

pressure cap wh ile the en gine is

at oper ating temperature. Wear

adequate protective clothing

(face sh ield, rubber gloves,

apron, and boots). Remove the

cap slowly to relieve pressure.

PERSONAL INJURY

To avoid injury from slipping and

falling, immediately clean up any

spilled liquids.

Air Intake System

Observe the following cau tions when

working on the air intake system.

PERSONAL INJURY

To avoid injury from hot surfac es,

wear protective gloves, or allow

engine to cool before removing

any component.

PERSONAL INJURY

To avoid injury from contact

with rotating parts when an

engine is operating with the air

inlet piping removed, install an

air inlet scree n sh i eld o ver the

turbocharger air inlet. The shield

prevents contact with rotating

parts.

8 All information subject to change without notice.

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Detroit Diesel 60, EPA04 Series 60 User manual

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